Fluid treatment apparatus

ABSTRACT

A fluid treatment apparatus ( 100 ) and method having a variety of interchangeable input/output cards ( 10 ) capable of communicating with a variety of parameters including analytical parameters. A programmable central processing unit ( 124 ), input/output cards ( 10 ), data bus ( 30 ), display ( 102 ), and keypad ( 104 ) are integrated into a single integrated apparatus ( 100 ). Analytical parameters are received directly by the appropriate input/output cards for direct communication with the central processing unit ( 124 ). The central processing unit also outputs control parameters through the input/output cards.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing of U.S. ProvisionalPatent Application Ser. No. 60/089,861 entitled AQUALYNX WATER TREATMENTAPPARATUS, filed on Jun. 19, 1998, and the specification thereof isincorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention (Technical Field)

The present invention relates to the field of fluid monitoring andtreatment apparatuses.

2. Background Art

Many different instruments are required to measure the parameters ofwastewater, process water, or other fluid being sampled. Maintainingthese individual components and tracking the data from these individualcomponents is cumbersome. For example, samplers, flow meters, pH meters,temperature gauges, conductivity and ORP meters, etc., are all used tomonitor and track the quality of wastewater, process water, or otherfluid being sampled. In fact, most water treatment monitoring systemstoday comprise an assortment of individual meters and gauges. Theseindividual components are not integrated.

Currently, microprocessor-based control systems are being used in modernindustrial processes, including water treatment applications andprogrammable logic controllers (PLCs) are microprocessor-based.Programmable logic controllers were designed to be amicroprocessor-based replacements for hardwired relay logic historicallyused in industrial control systems. PLCs are programmed to simulate thesame type of control that could be accomplished by sets of relays andtimers. This is referred to as logic control. Logic control allowscertain specific actions to occur based upon other actions orconditions. PLCs have the ability to quickly scan inputs and controloutputs based upon the condition of the inputs. However, most PLCs donot have any provisions for storing data (referred to as data logging)or for displaying data on a screen without an additional operatorinterface.

PLCs also do not have the ability to obtain data directly from watertreatment sensors such as pH, ORP, conductivity, etc. This means that anadditional meter or transmitter has to be installed between the PLC andthe appropriate sensor. A discrete signal is often sent from a relayoutput on a meter to a discrete input on the PLC. Alternatively, ananalog signal may be sent from the meter to an analog input on the PLC.Use of meters in addition to the PLC means additional expense,additional wiring, and additional programming since the meter will haveto be programmed for alarm set points and alarm deadband. In summary,current PLCs are used primarily for control. They tend to be difficultif not impossible to use for calculating, manipulating, displaying orstoring data. They cannot be used to obtain input directly from mostwater treatment sensors.

In conventional monitoring systems, it is common to have a number ofseparate meters monitoring the analytical parameters listed above. Eachof these meters may then produce an analog output, which is recorded bysome type of control device, such as a PLC. Many PLCs are designedhaving interchangeable input/output modules. These modules plug into a“rack” or a piece of hardware with multiple connections to some type ofdata bus, much like the ISA slots in a personal computer. However, inthe case of analytical parameters such as pH, oxidation reductionpotential (ORP), conductivity, dissolved oxygen, turbidity, corrosionrate, ion specific, etc., conventional systems monitor these parameterswith separate discrete instruments. These instruments then send asignal, usually some type of analog signal, to a standard input moduleon the PLC. Presently available systems do not have input/output modulesfor analytical parameters available for standard PLCs.

With a conventional PLC, the monitoring and control system is configuredby selecting the assorted meters necessary to monitor the parameters ofinterest. These are hardwired to the PLC and both the PLC and the metershave to be programmed. In the case of the present invention,configuration is done via software rather than hardwiring, andinput/output modules are used to monitor and control analyticalparameters as well as other parameters. The present invention alsoallows the user to log data as well as display data.

Patents which disclose devices designed to combine the differentconductivity meters, pH meters, ORP meters, flow meters, etc. but unlikethe present invention include U.S. Pat. No. 5,091,863, to Hungerford, etal., entitled Automatic Fluid Sampling and Flow Measuring Apparatus andMethod, which discloses a device to monitor sewer flows and which is tobe mounted inside a manhole. U.S. Pat. No. 5,172,332, to Hungerford, etal., entitled Automatic Fluid Sampling and Monitoring Apparatus andMethod, is essentially the same device as that in U.S. Pat. No.5,091,863 but includes broader program storage memory and data storagememory. U.S. Pat. No. 5,299,141, to Hungerford, et al., entitledAutomatic Fluid Monitoring and Sampling Apparatus and Method, againdiscloses the same device as in the prior two patents but includes aphotoelectric type sensor. U.S. Pat. No. 5,633,809, to Wissenbach, etal., entitled Multi-Function Flow Monitoring Apparatus with AreaVelocity Sensor Capability, again discloses a similar device to theprior three patents but includes input/output points. However, these arefixed. Additional analog inputs and discrete outputs cannot be added.All of these devices are to be used in monitoring sewer pipes and aremounted in manholes, and their primary purpose is for flow measurement.

Unlike the aforementioned devices, the present invention isreprogrammable even after the unit has been installed. The presentinvention is designed to be programmed for each application, includinglogic control functions. It can be used for any type of fluid monitoringand control, not just wastewater. The aforementioned parameters can allbe monitored directly from the sensor with the various input/outputcards without any additional instrumentation. The input/output cards areinterchangeable and selectable by the user and can be interfaceddirectly to the data bus from the various instruments. The applicationsfor this type of input/output card configuration are endless. Analyticalprocess parameters have not been directly monitored by devices in theprior art. Because it is compact and flexible, the present invention canbe mounted on a control panel with standard bracketing. This uniqueapparatus can be used to monitor streams in industrial settings as wellas in the field.

SUMMARY OF THE INVENTION (DISCLOSURE OF THE INVENTION)

The present invention is an integrated apparatus for monitoring andcontrolling fluid treatment having a central processing unit tomanipulate and control data and at least one interchangeableinput/output card for communication with sensor inputs and the centralprocessing unit. The apparatus optionally has a keypad for the user tocommunicate directly with the central processing unit. Variousinterchangeable input/output cards are available for the fluid treatmentapparatus. These cards include analog/pulse input cards, analog outputcards, digital input/output cards, conductivity input cards, pH/ORPinput cards, water treatment combination cards, temperature input cards,combination conductivity and resistivity input cards, pH input cards,ORP input cards, dissolved oxygen input cards, corrosion rate inputcards, turbidity input cards, particle counting input cards, modemcards, printer interface cards, memory cards, and serial communicationcards. The fluid treatment apparatus can have a data bus forcommunicating between the input/output cards and the central processingunit. A serial port is available for communicating with externaldevices. The fluid treatment apparatus is compact and integrated and canbe mounted on a control panel.

The software upon which the CPU operates can perform a variety ofcalculations, including but not limited to calculating differentialpressure, flow recovery, energy consumption, chemical usage, totaloperating time, total volume processed, salt rejection, temperaturedifferential, heat loss, and normalized data. The software is alsocapable of setting alarms and logging alarm events. By using thesoftware, the user can label inputs, establish ranges for inputs,establish alarm set points for inputs, designate alarm relays, setanalog output ranges, calculate results, store data, display real timedata, display stored data, and perform data transfer. The fluidtreatment apparatus also has internal memory to store data. A display isprovided for viewing data. Preferably the display is an LCD display.

At least one of the interchangeable input/output cards is capable ofdirectly communicating with analytical sensors. Preferably the apparatuscan communicate directly with conductivity sensors, pH sensors, ORPsensors, temperature sensors, dissolved oxygen sensors, turbiditysensors, ion specific sensors, and flow sensors.

Preferably PC-compatible software is used to program the centralprocessing unit. Passive backplane architecture is used in the apparatusand card guides are used for retaining the interchangeable input/outputcards.

The apparatus has applications in several technologies. Reverse osmosisoperations can be monitored and controlled with the apparatus with atleast one reverse osmosis vessel, at least one analytical sensor, and atleast one pressure pump in communication with each other and in directcommunication with the apparatus. A plurality of apparatuses can also benetworked and in communication with an industrial personal computer,sensors, and control devices, such as pumps and valves, for monitoringand controlling a plurality of fluid treatment applications.

Cooling towers can be monitored and controlled with the apparatus withthe apparatus in communication with the tower, chemical injection pump,and valves necessary for controlling the tower.

The unique configuration of the input/output cards capable ofcommunicating directly with analytical sensors and in turn communicatingthose inputs to the central processing unit has applications in othertechnologies. Analytical parameters can be monitored with the centralprocessing unit, data bus, and at least one input/output card to receivethe analytical parameters and communicate them to the central processingunit.

A method for controlling and monitoring fluid treatment involvesmanipulating fluid treatment data with the central processing unit ofthe apparatus, controlling fluid treatment with the central processingunit, communicating with sensor inputs with the interchangeableinput/output cards, and outputting control parameters with theinterchangeable input/output cards. The user can optionally communicatewith the central processing unit via a keypad. The input/output cardscan communicate with the central processing unit via a data bus. Datacan be communicated with external devices, such as printers, computersand the like, by communication through an optional serial port.Calculating fluid treatment parameters is accomplished by programmingthe central processing unit. The central processing unit can perform anumber of calculations including differential pressure, flow recovery,energy consumption, chemical usage, operating time, volume processed,salt rejection, temperature differential, heat loss, and normalizeddata. It can also set alarms and log alarm events. By programming thecentral processing unit, the user can label inputs, establish ranges forinputs, designate alarm relays, set analog output ranges, performcalculations, store data, display stored data, display real-time data,and perform data transfer. The user can further control and monitorapplications by displaying data on the screen of the apparatus andviewing such data. The user can also select and interchange the variousinput/output cards to tailor the apparatus to the desired application.

A primary object of the present invention is to provide the ability todirectly receive analytical parameters.

Another object of the present invention is to monitor and control avariety of fluid treatment parameters with one integrated programmableapparatus.

Yet another object of the present invention is to monitor and controlfluid treatment parameters from a central location mounted on a singlecontrol panel.

Still another object of the present invention is to provide anintegrated apparatus for monitoring and controlling fluid treatmentparameters that is easily programmed and simple to operate.

A primary advantage of the present invention is that individual metersand gauges are not necessary to monitor and control fluid treatmentparameters.

Other objects, advantages and novel features, and further scope ofapplicability of the present invention will be set forth in part in thedetailed description to follow, taking in conjunction with theaccompanying drawings, and in part will become apparent to those skilledin the art upon examination of the following, or may be learned bypractice of the invention. The objects and advantages of the inventionmay be realized and attained by means of the instrumentalities andcombinations particularly pointed out in the appended claims.

DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and form a partof the specification, illustrate several embodiments of the presentinvention and, together with the description, serve to explain theprinciples of the invention. The drawings are only for the purpose ofillustrating a preferred embodiment of the invention and are not to beconstrued as limiting the invention. In the drawings:

FIG. 1 is a block diagram of the preferred embodiment of the invention;

FIG. 2 is a perspective frontal view of the display module of thepresent invention;

FIG. 3 is a rear view of the display module showing input/outputconnectors of the present invention;

FIG. 4 is a perspective rear view showing the card guides of the presentinvention;

FIG. 5 is a perspective rear view of the display module and back plateof the present invention;

FIG. 6 is a schematic diagram of the terminal connections on the maincentral processing unit card of the present invention;

FIG. 7 is a schematic-block diagram of the terminal connections on theanalog/flow input card of the present invention;

FIG. 8 is a schematic-block diagram of the terminal connections on thedigital input/output card of the present invention;

FIG. 9 is a schematic-block diagram of the terminal connections on theconductivity input card of the present invention;

FIG. 10 is a schematic-block diagram of the terminal connections on thepH/ORP input card of the present invention;

FIG. 11 is a schematic-block diagram of the terminal connections on thewater treatment and reverse osmosis combination input card of thepresent invention;

FIG. 12 shows a conventional reverse osmosis system;

FIG. 13 shows a reverse osmosis system using the present invention;

FIG. 14 shows a networking application using the present invention;

FIG. 15 shows a cooling tower application using the present invention;

FIG. 16 is an electronic block diagram of the central processing unit ofthe present invention;

FIG. 17 is an electronic block diagram of the conductivity input card ofthe present invention;

FIG. 18 is an electronic block diagram of the pH/ORP input card of thepresent invention;

FIG. 19 is an electronic block diagram of the digital input/output cardof the present invention;

FIG. 20 is an electronic block diagram of the analog/pulse input card ofthe present invention;

FIG. 21 is an electronic block diagram of the modem card of the presentinvention;

FIG. 22 is an electronic block diagram of the water treatment andreverse osmosis combination input card of the present invention; and

FIG. 23 is an electronic block diagram of the analog output card of thepresent invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS (BEST MODES FOR CARRYING OUTTHE INVENTION)

The present invention is a programmable, integrated compact dataacquisition, monitoring, and control system designed for fluid treatmentapplications. It is capable of monitoring a variety of inputs, forexample pressure, conductivity, pH, ORP, temperature, and flow and isdesigned to replace the usual assortment of meters and gauges making upmost fluid treatment monitoring systems. Since it is an integratedmonitor, all of the operating parameters are examined by the sameinstrument. The apparatus can also calculate values such as differentialpressure, flow recovery, energy consumption, chemical usage, totaloperating time, total volume processed, salt rejection, temperaturedifferential, heat loss, and normalized data with the CPU. Alarm setpoints can be entered for both primary and calculated parameters andalarm events are logged to an internal alarm log. The present inventioncan also log operating data, transmit data via modem, or print data onan optional printer.

In the preferred embodiment, the fluid treatment apparatus is equippedwith a serial port which may be configured as either RS-232 or RS485.This allows the apparatus to communicate with a number of third-partydevices such as personal computers, PLCs, printers, modems, anddistributed control systems. The apparatus comes with appropriatesoftware for downloading data via direct connection or modem. PreferablyWindows 95 or comparable software is used. The apparatus is ideal for anumber of fluid and water treatment applications, including coolingtowers, boilers, reverse osmosis units, ion exchange units, reverseosmosis and ion exchange pretreatment systems, and wastewater treatment.

Passive backplane architecture provides versatility to the apparatus.The unit houses a central microprocessor connected to a passivebackplane containing a number of expansion slots. These slots may beequipped with one or more of a variety of input/output cards availablefor specific types of input and output. By selecting the appropriatedisplay/CPU unit along with the appropriate input/output card or cards,the end user can configure a monitoring system for a specificapplication. Many different input/output cards are available to choosefrom.

Example input/output cards include the following. A combination inputcard preferably receives inputs from two conductivity cells, twotemperature sensors for conductivity temperature compensation, four flowsensors, and four auxiliary analog inputs from four to twenty milliamps.A conductivity input card preferably receives inputs from twoconductivity cells and two temperature sensors for temperaturecompensation. A pH/ORP card preferably receives input from either two pHprobes, two ORP probes, or a combination of the two. It also receivesinputs from two temperature sensors for pH temperature compensation. Thedigital input/output card is preferably equipped with eight opticallyisolated digital inputs capable of receiving signals up to 48 volts ACor DC. It is also equipped with eight single pole single throw relaysable to withstand three amperes at 120 volts. The analog/flow input cardis a general purpose card capable of accepting eight four to twentymilliamp analog inputs (single-ended, non-isolated) and six flow inputs.The flow inputs are configured to accept open collector outputs fromHall effect type flow sensors. The analog output card is preferablyequipped with four non-isolated, single-ended, analog four to twentymilliamp outputs. The parallel printer interface card allows theapparatus to print data to any printer equipped with a parallelinterface. A serial communication card can also be programmed forspecific communication protocols such as Modbus, DeviceNet, Profibus,and others. A temperature card is available for a thermocouple, RTDresistor, and thermistor. An individual pH card is also available. Theapparatus also accommodates a conductivity and resistivity card. Anindividual ORP card can be used, as well as a dissolved oxygen card. Acorrosion rate card is available and is accomplished by means of linearpolarization resistance or other standard means. Turbidity and particlecounting cards can also be placed into the apparatus. A modem cardallows the apparatus to transmit data via modem when used in conjunctionwith data transfer software. These are just examples of the manydifferent input/output cards available and comprise only one embodimentof each. Many alternative embodiments for each input/output card wouldbe obvious to those skilled in the art.

Although many features and components can be used to configure theapparatus, the apparatus most preferably uses the following: a NEMA12-panel mounted enclosure, a Phillips 80C552 microprocessor (22megahertz), 128K SRAM with lithium backup, a 128K FLASH memory, a Dallasreal time clock, an RS-232/RS-485 serial port, a 20 by 16 character LCDdisplay with LED backlight, a 2 by 8 numeric keypad, a five amp and120/240 volt to 24 volt transformer or 24 volt DC power supply, andsoftware for system configuration and data transfer. Preferably,Windows-based software is used in the apparatus.

The software is used for two purposes. First, it provides a way in whichthe user can configure the hardware of the apparatus for a specificapplication. The software also allows the user to label individualinputs, establish ranges and alarm set points for each input, designatealarm relays for various parameters, and set analog output ranges forvarious parameters. Data transfer software is used for downloading dataeither by direct serial connection or remotely via modem. Datadownloaded from the apparatus may be saved in an ASCII delimited format.This makes it possible to read the data with virtually any spreadsheetprogram. The apparatus also includes a PCMCIA interface in the preferredembodiment. This hardware allows the apparatus to download data to astandard PCMCIA memory card. Data saved to the card may then be uploadedto any personal computer.

In the preferred embodiment, the entire fluid treatment apparatus isapproximately 5.25 inches wide, 5.25 inches high, and 6.25 inches deep.It weighs approximately three pounds. Power consumption for theapparatus is five amps at 24 volts AC or DC. The system can be equippedwith a 120/240 volt transformer or 24 volt DC power supply.

The software configuration for the present invention is preferably aWindows-based package. The user loads the software on a standardpersonal computer and starts designing the system by inputting theparameters to be monitored, including their names, units, scales, and soon. Next, any calculated values are included by typing in theappropriate formula. Alarms are then defined, including high and low setpoints and alarm deadbands. After the configuration is complete, theinformation is downloaded to the fluid treatment apparatus via a serialtransfer cable. Then the apparatus is ready for use. Frequently changedparameters such as alarm set points and deadbands may be changeddirectly from the keypad. The central processing unit (CPU) of theapparatus is different from those commonly used in PLCs. The CPU in thefluid treatment apparatus is powerful and equipped with a large amountof memory. This allows the apparatus to store a large amount of data.The software allows the CPU to be programmed in BASIC programminglanguage rather than ladder logic which is used by most PLCs. This meansthat the apparatus has the ability to easily calculate, store, andotherwise manipulate data.

A simple example of a logic statement might be as follows: “Start thefeed pump if the selector switch is in the auto position and if thelevel switch is in the low position. Start the high pressure pump tenseconds after starting the feed pump.” The BASIC source code used toperform this logic control would be as follows:

10 XIH 016: XIL 017: OTE 000 REM starts feed pump 11 XIH 000: DLY 000,010: OTE 002 REM delays start of HP pump 12 GO TO 10

These logic instructions are entered during the configuration procedurewith the Windows configuration software. Unlike most PLCs, the fluidtreatment apparatus serves as its own operator interface. Messages maybe programmed into logic portion of the configuration to appear on thescreen during operation. Also, the status of all input/output points maybe viewed by selecting the appropriate screen from the fluid treatmentapparatus main menu. Preset values for counters and timers may bechanged directly from the keypad without having to connect to a laptoppersonal computer or handheld programming unit. Therefore configurationfor the apparatus' monitoring and control is done via software ratherthan through hardwiring. This data can then be processed and stored andtransmitted via modem or a serial connection. The entire operationoccurs at the fluid treatment apparatus.

The fluid treatment apparatus may be programmed to do any calculations.This allows data to be calculated automatically and in real time, thuslowering manpower requirements and providing up-to-date information. Atypical example is the calculation of normalized permeate flow fromreverse osmosis units.

The apparatus also stores operating data to internal memory for laterretrieval with any personal computer via serial port or modem, or storedto an optional memory card. The memory card may also be used foruploading the system configuration. Furthermore, the fluid treatmentapparatus logs all alarm events, which may be viewed directly on thefluid treatment apparatus display. Discrete input/output status may beviewed on the display during operation to facilitate troubleshootingwithout having to connect a personal computer or handheld programmingunit to the controller. The ability to program and display statusmessages eliminates the use of PLC operator interfaces. The modeminput/output card allows communication to personal computers viastandard telephone lines. A serial port allows networking via serialcommunication. As stated previously, the fluid treatment apparatus iscapable of directly monitoring a number of fluid treatment analyticalprocess parameters such as conductivity, pH, ORP, temperature, dissolvedoxygen, turbidity, ion specific, and flow. It is also capable ofmonitoring virtually any other parameter via standard four to twentymilliamp analog signals or via discrete signals.

The apparatus is also capable of calculating additional data based uponraw process data. These values, along with raw data, may then be loggedfor future evaluation. The apparatus can also be used to control processconditions. This may be as simple as opening and closing relay contactsbased upon alarm conditions or it may be more elaborate and involvelogic control for a particular process. Each fluid treatment apparatusis programmed separately and for a particular application.

Raw operating data is logged into an internal memory location. Thelogging interval for the data is preferably once every 30 minutes. Dueto the large volume of data acquired in the data log, the data is notviewable on the LCD of the apparatus. It can, however, be downloaded byconnecting a personal computer to the serial port (either locally or viamodem) with the software.

In the preferred embodiment, operation of the apparatus is very simplesince it is completely menu driven, with the only exception being sensorcalibration. Upon power up, the apparatus will display a main menu fromwhich the operator may choose from a number of screens by pressing theappropriate key on the keypad. Data screens allow the user to observereal time operating data. A settings menu allows changes to parameterssuch as set points, deadbands, time delays, flow sensor K factors, andconductivity correction factors, analog ranges and scales, and timedelays. An access code is entered in order to change settings. K factorsmust be entered for all flow sensors providing a pulse signal. The Kfactor is defined as the number of pulses produced by the flow sensor byevery gallon that passes through the sensor. The alarm history screenallows the operator to view alarms logged by the fluid treatmentapparatus. An output status screen allows the operator to view thestatus of output relays. The input screen allows the operator to viewthe status of discrete inputs and internal memory bits. These are justsome of the screens and capabilities of the fluid treatment apparatus,all of which are controlled by BASIC software. All parameters aremonitored and displayed by one panel-mounted apparatus. This means thata number of calculated values can be continuously monitored, recorded,and displayed, a feature important in monitoring and controlling watertreatment systems. A Windows-based configuration application is providedas an alternative embodiment for the fluid treatment apparatus in placeof the direct BASIC programming embodiment.

Attention is now turned to the figures. FIG. 1 shows a basic blockdiagram of one embodiment of fluid treatment apparatus 100. Exampleinput/output cards are shown generally at 10. The input/output cards canbe water treatment combination card shown at 70, conductivity card 72,pH/ORP card 74, digital input/output card 76, analog output card 78,analog/pulse input card 80, and, modem card 82. CPU 124 communicateswith input/output cards 10 via I/O card data bus 30. Bus connectors areshown generally at 40. CPU 124 communicates with a 20 by 16 characterLCD display 102 and 2 by 8 keypad 104. Of course, these dimensions arevariable, and FIG. 1 only shows a preferred embodiment of the presentinvention.

FIG. 2 is a perspective view of fluid treatment apparatus 100. Display102 displays various parameters and directs the user through variousmenus and user input operations. Keypad 104 is used to program andoperate the apparatus. Attachment points 106 allow clamps to be attachedfor panel mounting.

FIG. 3 shows a rear view of fluid treatment apparatus 100. The backplanein fluid treatment apparatus 100 is equipped with six ports whichconsist of CPU connector port 110, and input/output card connector ports112, 114, 116, 118, and 120. CPU connector port 110 is always occupiedby the CPU card. Card guides shown generally at 108 provide guides forsliding the CPU and various input/output cards into the rear of fluidtreatment apparatus 100.

FIG. 4 shows fluid treatment apparatus 100 and CPU card 124 as it isslid into the rear of fluid treatment apparatus 100 via one of cardguides 108. Serial port 132 provides communication with externaldevices. As shown in FIG. 5, once the CPU and selected input/outputcards are placed in the rear of fluid treatment apparatus 100, backplate 126 is screwed via screws 130, 130′, 130″, and 130′″ and screwholes 128, 128′, 128″, and 128′″ onto the rear of fluid treatmentapparatus 100.

FIG. 6 shows the terminal connections on the main CPU card 124 as aschematic block diagram. Power supply 204 provides either 24 volts AC orDC. The two power inputs are bipolar, i.e., positive power may beconnected to either of the two terminals. Fuse 202 is used to protectthe power connection to CPU card 124. Power, ground, and RS-485connections are shown generally at 206. CPU card 124 should be properlygrounded to earth ground. CPU card 124 serves several functions,including storing and executing the main control program, communicatingwith the input/output cards via the bus, communicating with externaldevices via serial port 132, receiving input from keypad 104, andsending output to display 102.

Analog/flow input card 80 terminal connections are shown as a schematicblock diagram in FIG. 7. This card is designed to be used with flowsensors equipped with an open collector, Hall effect output. Theanalog/flow input card is a general purpose card which allows fluidtreatment apparatus 100 to receive input from other devices producingpreferably a four to twenty milliamp signal. It also may be used toreceive input from devices producing a sinking pulse by means of a Halleffect sensor. In the preferred embodiment of the invention, one fluidtreatment apparatus 100 will support up to eight analog/flow inputcards. The analog/flow input card has eight single-ended 12-bit inputsat four to twenty milliamps, and eight sinking pulse 12 to 24 volts DC.Power required for the analog/flow input card is either five volts DC or24 volts DC via the bus connection. Twenty-four volts DC is supplied totwo wire transmitters via terminal connectors. This card is programmedusing either BASIC or Windows configuration software. Hall effect flowsensors have three lead connections 302, one for positive DC, one fornegative DC, and one for the return signal for sinking pulse. Terminalblocks 304, for example, DIN rail style, should be used to connectterminals to field wiring. This allows smaller gauge wire to be used onthe terminals. Flow inputs may also be used as discrete inputs 306, suchas for hand switches and float switches. Input 306 is high whenconnected to the low side of the DC supply, sinking input. Some devicesproduce their own four to twenty milliamp signal without requiring powerfrom fluid treatment apparatus 100. These devices may be used with theanalog/flow input card and connected at 308. However, they must producean isolated output of sufficient amperage. These devices are interfacedby connecting the positive output of the device to the analog input ofthe card. The negative side of the device is connected to the V−terminal of the card. Analog devices should be connected to fluidtreatment apparatus 100 with shielded cable 310, 310′. The shield of thecable should be grounded but only at one end of the cable. Two wireanalog transmitters at four to twenty milliamps may be powered by the 24volt DC output 312 from the analog/flow input card. The positive side ofthe transmitter is connected to the V+ terminal of the card. Thenegative side of the transmitter is connected to the analog input.

Digital input/output card 76 terminal connections are shown as aschematic block diagram in FIG. 8. Digital input/output card 76 is ageneral purpose card which allows fluid treatment apparatus 100 toreceive discrete inputs from devices such as level switches, handswitches, float switches, push buttons, selector switches, pressureswitches, and PLC relay outputs. It is also equipped with relay outputsto control pumps, motors, lights, valves, and other devices. In thepreferred embodiment of the invention, one fluid treatment apparatus 100will support up to eight digital input/output cards. The digitalinput/output card has eight optically isolated inputs, two groups offour, with one common connection per group. Input voltage is limited to24 volts AC or DC. The output of digital input/output card 76 is eightSPST (single pole single throw) relays in two groups of four, with onecommon connection per group. Switched voltage is limited to 24 volts ACor DC, with a maximum current of two amps per common connection. Relaycontacts are protected with MOVs. Digital input/output card 76 requiresfive volts DC, 24 volts DC via the bus connection. Inputs with voltagesgreater than 24 volts AC or DC must be interfaced through an interposingrelay 322 or isolator. Terminal blocks 324, for example, DIN rail style,should be used to connect terminals 324 to field wiring. This allowssmaller gauge wire to be used on the terminals 324. Low voltage discreteinputs 326, less than 24 volts AC or DC, may be connected directly tothe inputs. Applications that require switching of voltages greater than24 volts AC or DC or switching of high loads, greater than two amps peroutput group, must use interposing relays 328. Low voltage, low loadoutputs may be switched directly by output relays 330. Relays 322, 328and 330 enable fluid treatment apparatus 100 to control devices such assolenoid valves, motor starters, indicator lights, and alarms. It isapparent that, when properly programmed, fluid treatment apparatus 100can replace PLCs in most water treatment applications.

Conductivity input card 72 terminal connections are shown generally inFIG. 9 as a schematic block diagram. Conductivity input card 72 allowsfluid treatment apparatus 100 to monitor two standard conductivitycells. The cells are equipped with 1,000 ohm platinum RTD resistors fortemperature compensation in the preferred embodiment. It is also able toreceive input from four other devices producing a four to twentymilliamp signal 342 and from three devices producing a sinking pulse bymeans of a Hall effect sensor. In the preferred embodiment, one fluidtreatment apparatus 100 will support up to eight conductivity inputcards 72 and contains two electrode conductivity cells inputs, two 1,000ohm platinum RTD resistor sensors, four single-ended 12-bit inputs atfour to twenty milliamps, and three sinking pulse inputs at 12 to 24volts DC. Conductivity input card 72 requires five volts DC or 24 voltsDC via the bus connection, and supplies 24 volts DC to two wiretransmitters via terminal connectors. Shielded cable 344 is shown toconnect analog devices to fluid treatment apparatus 100. Two wire analogtransmitters, four to twenty milliamps, may be powered by the 24 volt DCoutput 346 from conductivity input card 72. Hall effect flow sensorshave three lead connections 348, one for DC+, one for DC−, and one forthe return signal, sinking pulse. Terminal blocks 350, for example, DINrail style, should be used to connect the fluid treatment apparatusterminals to field wiring. This allows smaller gauge wire to be used onthe terminals. Proper ranges for each conductivity channel are set bydip switches on the card.

PH/ORP input card 74 terminal connections are shown generally in FIG. 10as a schematic block diagram. PH/ORP input card 74 allows fluidtreatment apparatus 100 to monitor two standard pH electrodes, two ORPelectrodes, or a combination of the two in the preferred embodiment. PHprobes are equipped with 1,000 ohm platinum RTD resistors 362, 362′ iftemperature compensation is required. In the preferred embodiment, onefluid treatment apparatus 100 will support up to eight pH/ORP inputcards 74. Low impedance coaxial cable 364 should be used to connect pHand ORP probes directly to pH/ORP card 74. The input for pH/ORP card 74is two high impedance analog voltage inputs at plus or minus 1,000millivolts for pH or ORP electrodes, and two 1,000 ohm platinum RTDresistor temperature sensors. PH/ORP input card 74 is powered by fivevolts DC or 24 volts DC via the bus connection.

Water treatment and RO combination input card 70 terminal connectionsare shown as a schematic block diagram in FIG. 11. Water treatmentcombination card 70 allows fluid treatment apparatus 100 to monitor onestandard conductivity cell, one pH or ORP electrode, and three sinkingpulse discrete inputs in the preferred embodiment. Conductivity and pHsensors are equipped with 1,000 ohm platinum RTD resistors fortemperature compensation in the preferred embodiment. Water treatmentcombination card 70 also has four SPST relay outputs. In the preferredembodiment, one fluid treatment apparatus 100 will support up to eightwater treatment combination cards 70. Water treatment combination card70 has one two-electrode conductivity cell input, one high impedanceanalog voltage input for pH or ORP electrodes, two 1,000 ohm platinumRTD resistor temperature sensors, and three sinking pulse, 12 to 24volts DC inputs. The output of water treatment combination card 70contains four SPST relays. Water treatment combination card 70 ispowered by five volts DC or 24 volts DC via the bus connection, and 24volts DC is supplied to Hall effect sensors via the terminal connectors.Sensors 382 should be connected directly to a conductivity card. PH andORP probes 384 should be connected directly to a pH/ORP card by means oflow impedance coaxial cable. Terminal blocks 386 are used to connectfluid treatment apparatus terminals to field wiring. Again, this allowssmaller gauge wire to be used on the fluid treatment apparatusterminals. Hall effect flow sensors have three lead connections 388, onefor positive DC, one for negative DC, and one for the return signal orsinking pulse. Flow inputs may also be used as discrete inputs 390, suchas for hand switches and float switches. The input is high whenconnected to the low side of the DC supply, sinking input. If pHreadings are to be temperature compensated, the pH probe is equippedwith a 1,000 ohm platinum RTD resistor 392.

A modem card is also used with fluid treatment apparatus 100 tocommunicate via standard analog telephone lines.

Fluid treatment apparatus 100 is designed to be panel mounted in varioustypes of electrical enclosures with standard mounting brackets. Althoughfluid treatment apparatus 100 is shown using card guides 108 to mountthe different input/output cards, other configurations for fluidtreatment apparatus 100 are available. For example, a separate card cagecan be used to store the input/output cards and the input/output cardscould alternatively be connected to fluid treatment apparatus 100 with aribbon cable. However, mounting the various input/output cards in therear of fluid treatment apparatus 100 provides a compact and simplesystem which is small enough to be panel-mounted in an electricalenclosure.

Attention is now turned to FIGS. 16 to 23, where various input/outputcards are shown as electrical block diagrams. FIG. 16 shows CPU 124 asan electrical block diagram. Microprocessor 437 is equipped with memory436 and real time clock 435. Microprocessor 437 is interfaced withkeypad 104 and LCD 102. Microprocessor 437 communicates with the variousI/O cards by means of I/O card data bus 30. Microprocessor 437 may alsocommunicate with other devices by means of RS 232 or RS 485 serial ports433. CPU 124 also includes switching power supply 434 which provides 5volts DC and 24 volts DC to the I/O cards. It also provides referencevoltages of 1 volt DC and 4 volts DC.

FIG. 17 shows conductivity card 72 as an electrical block diagram. Eightchannel analog to digital converter 440 is connected to the isolatedinput circuitry for measuring the conductivity across the probe ofconductivity measuring circuit 438. Analog to digital converter 440 isalso connected to RTD measuring circuit 439 and other analog inputs.Typically, two conductivity measuring circuits 438 and RTD measuringcircuits 439 are on one conductivity card. Conductivity measuringcircuit 438 receives 24 volt DC power from power supply 434 from CPU124. Analog to digital converter 440 also receives reference voltagesfrom power supply 434 from CPU 124. Microprocessor 441 in conductivitycard 72 receives data from analog to digital converter 440 in additionto external pulse signals from flow sensors and communicates this datato CPU 124 via data bus 30.

FIG. 18 shows pH/ORP card 74 as an electrical block diagram. Eightchannel analog to digital converter 460 is connected to the isolatedinput circuitry for measuring the pH or ORP from probe of pH/ORPmeasuring circuit 442. Analog to digital converter 460 is also connectedto RTD measuring circuit 472. Typically, two pH/ORP measuring circuits442 and RTD measuring circuits 472 are on one pH/ORP card. The pH/ORPmeasuring circuit 442 receives 24 volt DC power from power supply 434from CPU 124. Analog to digital converter 460 receives referencevoltages from power supply 434 from CPU 124. Microprocessor 453 inpH/ORP card 74 receives data from analog to digital converter 460 andcommunicates this data to CPU 124 via data bus 30.

FIG. 19 shows the digital I/O card 76 as an electrical block diagram.Microprocessor 454 in digital I/O card 76 receives data from optoisolator 443 and communicates this data to CPU 124 via data bus 30.Microprocessor 454 receives data via data bus 30 and communicates thisdata to relay driver 444 which in turn controls the state of eight SPSTrelays.

FIG. 20 shows analog/pulse input card 80 as an electrical block diagram.Microprocessor 455 in analog/pulse input card 80 receives discrete orpulse data from opto isolator 470 and communicates this data to CPU 124via data bus 30. Analog to digital converter 462 is connected to eightanalog inputs and sends data to microprocessor 455. Analog to digitalconverter 462 receives reference voltages from power supply 434 from CPU124.

FIG. 21 shows modem card 82 as an electrical block diagram. Modem module448 is connected to a standard analog telephone line and sends data tomicroprocessor 456 which in turn transmits and receives data via an RS232 serial port 446. Serial port switch 447 allows other devices tocommunicate with serial port 446 when the modem is not in use.Microprocessor 456 responds to commands received from CPU 124 via databus 30. Status indicator lights 449 show the status of modem functions.

FIG. 22 shows water treatment combination card 70 as an electrical blockdiagram. Eight channel analog to digital converter 464 is connected tothe isolated input circuitry for measuring the pH or ORP from the probeof pH/ORP measuring circuit 466. Analog to digital converter 464 is alsoconnected to the isolated input circuitry for measuring the conductivityacross the probe of conductivity measuring circuit 468. Analog todigital converter 464 is also connected to two RTD measuring circuits474. The pH/ORP measuring circuit 466 and conductivity measuring circuit468 receive 24 volt DC power from power supply 434 from CPU 124. Analogto digital converter 464 receives reference voltages from power supply434 from CPU 124. Microprocessor 457 in water treatment combination card70 receives data from analog to digital converter 464 and communicatesthis data to CPU 124 via data bus 30.

FIG. 23 shows analog output card 78 as an electrical block diagram.Microprocessor 458 receives data from CPU 124 via data bus 30. Digitalto analog converters 450 convert the data to analog signals. Thesesignals are sent to field devices by means of isolated voltage tocurrent converters 451.

The unique configurations of conductivity card 72, pH/ORP card 74, andwater treatment combination card 70—in particular the pH/ORP measuringcircuits, conductivity measuring circuits, and RTD measuringcircuits—which allow the cards to directly receive analytical parametershas applications not only in the fluid treatment apparatus but in otherfields as well. The ability to receive analytical parameters directlyinto the apparatus is entirely new to the field of computers andmonitoring equipment. Variations upon these embodiments forcommunicating with these particular parameters as well as other types ofanalytical parameters will be obvious to those skilled in the art.

Industrial Applicability

The invention is further illustrated by the following non-limitingexamples.

FIG. 12 shows a conventional reverse osmosis system. Reverse osmosisvessels are shown generally at 400 and are monitored by pressure gauges420 and flow meters 422. Various devices are used to monitor the entiresystem, including conductivity 402, pH 404, ORP 406, flow 408, pressure410, and temperature 412, which in turn communicate with PLC 414. ThePLC then controls motorized valves 416 and high pressure pump 418. Withthis type of system, many different gauges, meters and discrete devicesare required to monitor and control the system.

FIG. 13 shows an improvement on the conventional reverse osmosis systemof FIG. 12 by using fluid treatment apparatus 100 of the presentinvention. Fluid treatment apparatus 100 communicates directly withanalytical sensors on reverse osmosis vessels 400 and directly withmotorized valves 416. Apparatus 100 also communicates directly with highpressure pump 418. With this configuration, cost is reduced. There arefewer wires, fewer pipes, and no PLC or PLC operator interface isrequired. Apparatus 100 is able to calculate values such as normalizedpermeate flow, differential pressure, and salt rejection and can alsolog data. Fluid treatment apparatus 100 may be connected to anothersystem via the modem communication.

FIG. 14 shows another application of fluid treatment apparatus 100 ofthe present invention. In this example, three apparatuses 100, 100′,100″, are networked in a reverse osmosis system. Fluid is pretreated at422 and communicates directly with apparatus 100. Reverse osmosisvessels 400 communicate directly with apparatus 100′ and post-treatmentoccurs at 422, which also communicates directly with the network viaapparatus 100″. All three apparatuses 100, 100′, and 100″ communicatewith industrial personal computer 426. With such a networking system,cost is reduced and the entire treatment system is controlled andmonitored from a central position. Less wiring is required and theability to interface with existing control systems is accomplished.

FIG. 15 demonstrates yet another application for fluid treatmentapparatus 100. In this application, apparatus 100 communicates directlywith cooling tower 428, chemical injection pump 432, and valve 430. Withthis system, chemical injection can be controlled and chemical costs aredecreased. This system can also be remotely monitored via the modemconnection.

The preceding examples can be repeated with similar success bysubstituting the generically or specifically described operatingconditions of this invention for those used in the preceding examples.

Although the invention has been described in detail with particularreference to these preferred embodiments, other embodiments can achievethe same results. Variations and modifications of the present inventionwill be obvious to those skilled in the art and it is intended to coverin the appended claims all such modifications and equivalents. Theentire disclosures of all references, applications, patents, andpublications cited above are hereby incorporated by reference.

What is claimed is:
 1. An integrated apparatus for monitoring fluidtreatment, said apparatus comprising: a programmable central processingunit for manipulating data and controlling fluid treatment; at least oneinterchangeable input/output card for communicating with sensor inputsand said central processing unit; a data bus for communicating said atleast one interchangeable input/output card with said central processingunit; a keypad for communicating with said central processing unit; adisplay for viewing data; at least one reverse osmosis vessel; at leastone analytical sensor for monitoring said reverse osmosis vessel; and atleast one pressure pump in communication with said apparatus, saidreverse osmosis vessel and said central processing unit.
 2. Theapparatus of claim 1 further comprising: an industrial personal computerfor networking a plurality of additional devices; at least one sensorfor monitoring a fluid treatment application and in communication withsaid personal computer via said additional devices; and at least onecontrol device for controlling said fluid treatment application.
 3. Theapparatus of claim 1 further comprising: a cooling tower incommunication with said central processing unit; at least one chemicalinjection pump in communication with said apparatus; and at least onevalve in communication with said central processing unit.
 4. Anintegrated apparatus for monitoring fluid treatment, said apparatuscomprising: a programmable central processing unit for manipulating dataand controlling fluid treatment; at least one interchangeableinput/output card for communicating with sensor inputs and said centralprocessing unit; a data bus for communicating said at least oneinterchangeable input/output card with said central processing unit; akeypad for communicating with said central processing unit; a displayfor viewing data; an industrial personal computer for networking aplurality of additional devices; at least one sensor for monitoring afluid treatment application and in communication with said personalcomputer via said additional devices; and at least one control devicefor controlling said fluid treatment application.
 5. An integratedapparatus for monitoring fluid treatment, said apparatus comprising: aprogrammable central processing unit for manipulating data andcontrolling fluid treatment; at least one interchangeable input/outputcard for communicating with sensor inputs and said central processingunit; a data bus for communicating said at least one interchangeableinput/output card with said central processing unit; a keypad forcommunicating with said central processing unit; a display for viewingdata; a cooling tower in communication with said central processingunit; at least one chemical injection pump in communication with saidapparatus; and at least one valve in communication with said centralprocessing unit.